배관응력해석 및 유한요소해석에 의한 SNG플랜트의 리스크 관리 위치 선정 Identifying Risk Management Locations for Synthetic Natural Gas Plant Using Pipe Stress Analysis and Finite Element Analysis원문보기
최근 합성천연가스(synthetic natural gas, SNG)의 사용과 합성천연가스를 생산하는 플랜트의 실증 운영이 증가하고 있다. SNG 플랜트는 다양하게 개발된 여러 합성 공정 기술이 적용되고 있으며, 이러한 공정의 특성상 고온, 고압의 운전 조건을 가진다. 기존 여러 연구들은 주로 합성천연가스 생산을 위한 화학적 합성 공정의 변수와 공정 최적화에 대한 연구에 집중되어 왔다. 이에 비해, 기존 산업 플랜트와는 다소 차별되는, 공정 특성으로 인한 SNG 플랜트의 기계적 손상과 유지보수 기법에 대한 연구는 많지 않다. 본 연구에서는 SNG플랜트의 주요 배관계통에 대해 ASME B31.3에 의거한 배관 시스템 응력 해석을 수행하였다. 또한 특이 부위에 대해 상세 국부 응력 해석을 수행하였다. 해석 결과로부터 배관 주요부위 중 파손 리스크가 높은 취약부의 위치를 선정하였다. 이 위치들은 배관 위험도 관리 대상으로 활용할 수 있다. 배관 시스템 응력 해석은 설계 운전조건과 실제 운전조건을 고려하여 수행되었다. 배관 시스템 응력 해석을 통해 도출된 주요 부위에 대해서는 국부적 상세 응력 해석을 위해 유한 요소 해석이 수행되었다. 발생되는 상세 응력 값은 가스화 반응기 및 하부 곡관부 대한 ASME B31.3 코드 표준을 만족하였다. 하부 곡관부의 경우 수직 변위를 제한하는 것이 구조적으로 안전 향상에 좋을 것으로 파악되었다. 수행된 해석결과는 향후 위험도 기반 유지 보수 검사 및 안전 운영에 대해 기반 정보로 사용될 수 있을 것으로 판단된다.
최근 합성천연가스(synthetic natural gas, SNG)의 사용과 합성천연가스를 생산하는 플랜트의 실증 운영이 증가하고 있다. SNG 플랜트는 다양하게 개발된 여러 합성 공정 기술이 적용되고 있으며, 이러한 공정의 특성상 고온, 고압의 운전 조건을 가진다. 기존 여러 연구들은 주로 합성천연가스 생산을 위한 화학적 합성 공정의 변수와 공정 최적화에 대한 연구에 집중되어 왔다. 이에 비해, 기존 산업 플랜트와는 다소 차별되는, 공정 특성으로 인한 SNG 플랜트의 기계적 손상과 유지보수 기법에 대한 연구는 많지 않다. 본 연구에서는 SNG플랜트의 주요 배관계통에 대해 ASME B31.3에 의거한 배관 시스템 응력 해석을 수행하였다. 또한 특이 부위에 대해 상세 국부 응력 해석을 수행하였다. 해석 결과로부터 배관 주요부위 중 파손 리스크가 높은 취약부의 위치를 선정하였다. 이 위치들은 배관 위험도 관리 대상으로 활용할 수 있다. 배관 시스템 응력 해석은 설계 운전조건과 실제 운전조건을 고려하여 수행되었다. 배관 시스템 응력 해석을 통해 도출된 주요 부위에 대해서는 국부적 상세 응력 해석을 위해 유한 요소 해석이 수행되었다. 발생되는 상세 응력 값은 가스화 반응기 및 하부 곡관부 대한 ASME B31.3 코드 표준을 만족하였다. 하부 곡관부의 경우 수직 변위를 제한하는 것이 구조적으로 안전 향상에 좋을 것으로 파악되었다. 수행된 해석결과는 향후 위험도 기반 유지 보수 검사 및 안전 운영에 대해 기반 정보로 사용될 수 있을 것으로 판단된다.
While they are becoming more viable, synthetic natural gas (SNG) plants, with their high temperatures and pressures, are still heavily dependent on advancements in the state-of-the-art technologies. However, most of the current work in the literature is focused on optimizing chemical processes and p...
While they are becoming more viable, synthetic natural gas (SNG) plants, with their high temperatures and pressures, are still heavily dependent on advancements in the state-of-the-art technologies. However, most of the current work in the literature is focused on optimizing chemical processes and process variables, with little work being done on relevant mechanical damage and maintenance engineering. In this study, a combination of pipe system stress analysis and detailed local stress analysis was implemented to prioritize the inspection locations for main pipes of SNG plant in accordance to ASME B31.3. A pipe system stress analysis was conducted for pre-selecting critical locations by considering design condition and actual operating conditions such as heat-up and cool-down. Identified critical locations were further analyzed using a finite element method to locate specific high-stress points. Resultant stress values met ASME B31.3 code standards for the gasification reactor and lower transition piece (bend Y in Fig.1); however, it is recommended that the vertical displacement of bend Y be restricted more. The results presented here provide valuable information for future risk based maintenance inspection and further safe operation considerations.
While they are becoming more viable, synthetic natural gas (SNG) plants, with their high temperatures and pressures, are still heavily dependent on advancements in the state-of-the-art technologies. However, most of the current work in the literature is focused on optimizing chemical processes and process variables, with little work being done on relevant mechanical damage and maintenance engineering. In this study, a combination of pipe system stress analysis and detailed local stress analysis was implemented to prioritize the inspection locations for main pipes of SNG plant in accordance to ASME B31.3. A pipe system stress analysis was conducted for pre-selecting critical locations by considering design condition and actual operating conditions such as heat-up and cool-down. Identified critical locations were further analyzed using a finite element method to locate specific high-stress points. Resultant stress values met ASME B31.3 code standards for the gasification reactor and lower transition piece (bend Y in Fig.1); however, it is recommended that the vertical displacement of bend Y be restricted more. The results presented here provide valuable information for future risk based maintenance inspection and further safe operation considerations.
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가설 설정
Due to the its support type, pipe B is relatively stiff and this increases the effect of pipe C on bend Y as it has more free space to move on as it can be seen in Fig. 6. All components were within the acceptable stress range; however, three out of the five highest stress values in the entire system were found on the gasification reactor at design conditions. For the gasification reactor, hoop stress values were dominant.
제안 방법
Design temperature and pressure values (343°C and 5.6 MPa, respectively) were the main analysis parameters; however, operating, start-up, and cool-down temperatures were also used during the analysis to check if there were any stress differences large enough to cause fatigue failure at any location.
0. Design temperature and pressure values as well as start-up, cool-down, and operational skin temperatures were applied.
1994; Hirano 2006). First, a pipe system stress analysis was conducted for identifying critical locations at which relatively high stress were generated during operation. For this, AutoPIPE V8i was used in accordance with the ASME B31.
For the crude pipe system stress analysis, AutoPIPE V8i was used at design temperature and pressure values as well as for start-up, cool-down, and operational skin temperatures. Parts that were critical according to the ASME B31.3 process piping design code and which are in a mechanical disadvantage, were reevaluated using the commercial FEA program ANSYS 16.0. Design temperature and pressure values as well as start-up, cool-down, and operational skin temperatures were applied.
3 process piping design code. Subsequently, a finite element analysis(FEA) was conducted for these critical locations using ANSYS 16.0 Workbench to get a better understanding of cause of the high stress and the distribution of the high stress points for future inspections and maintenance.
This paper presents the two step pipe stress analysis (Yoon et al. 2015) of an SNG plant under operation for inspection location selection similar to risk based inspection(RBI) (Dou et al. 2017; Chang et al. 2005) in the most basic sense however it only focuses on stress analysis. Plant components selected for consideration are those that would have the most serious effect on the plant in case of a malfunctioning or wrong operation (Keiser et al.
대상 데이터
The bottom was not restricted in any direction. The operational weight of the reactor was distributed into two sections: the slender slug grinder pipe for 101.3 tons and the remaining parts including the left and right sleeves and the nozzle connected to the fixed support for 544.3 tons. The design pressure value was set as the internal gas pressure.
이론/모형
As can be seen in Fig 3, modelling of the inner lining was also excluded here as refractory linings are not direct load-bearing components. As the bend Y is not directly connected to any support, the moment and force values acting on both of its ends were calculated and integrated into the model according to the initial pipe system stress analysis results at run points (AutoPIPE, 2011). Designing this component to include some parts of the pipe B was favorable as that enabled the use of these run points.
First, a pipe system stress analysis was conducted for identifying critical locations at which relatively high stress were generated during operation. For this, AutoPIPE V8i was used in accordance with the ASME B31.3 process piping design code. Subsequently, a finite element analysis(FEA) was conducted for these critical locations using ANSYS 16.
From the ASME Boiler and Pressure Vessel Code, Section II, Part D (American Society of Mechanical Engineers, 2010), the time dependent properties of SA516-70 were obtained, as they were necessary for the analysis. This data can be seen in the plot in Fig.
후속연구
The results obtained provide valuable information for prioritizing future inspection points. For the remaining parts of the system, further analysis is necessary to determine their criticality in terms of the entire system.
참고문헌 (18)
ANSYS(R) Academic Research, Release 16.0, 2015
ASME Boiler and Pressure Vessel Code II Part D: Properties. ASME, NY, USA; 2010.
ASME Boiler and Pressure Vessel Code, Section VIII, Division 2, Part 5, ASME, 2001.
AutoPIPE Version 8i SELECTseries3 release 9.4. User's manual. Bentley 2011
Chang, M.K. et al., 2005. Application of risk based inspection in refinery and processing piping. Journal of Loss Prevention in the Process Industries, 18(4-6), pp.397-402
Dou, Z. et al., 2017. Applications of RBI on leakage risk assessment of direct coal liquefaction process. Journal of Loss Prevention in the Process Industries, 45, pp.194-202
Hirano, T., 2006. Gas explosions caused by gasification of condensed phase combustibles. Journal of Loss Prevention in the Process Industries, 19 (2-3), pp.245-249
Huo, J. et al., 2013. Feasibility analysis and policy recommendations for the development of the coal based SNG industry in Xinjiang. Energy Policy, 61, pp.3-11
Koytsoumpa, E.I. et al., 2015. Modelling and assessment of acid gas removal processes in coalderived SNG production. Applied Thermal Engineering, 74, pp.128-135
Swain, P.K., Das, L.M. & Naik, S.N., 2011. Biomass to liquid: A prospective challenge to research and development in 21st century. Renewable and Sustainable Energy Reviews, 15(9), pp.4917-4933
Yoon, K.B. et al., 2016. Creep cracking and damage assessment in P91 and P92 piping system. EPRI 2nd Asia-Pacific Workshop: Service experience of creep strength enhanced ferritic steels, Eastern & Oriental Hotel, Penang Malaysia March 9-11
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